• Aleris Operating System (AOS) Reliable Assets Specialist - Continuous Improvement

    Relocation Available
    Position Type
    Full Time
  • Overview / Job Summary

    Aleris is a global leader in the manufacture and sale of aluminum rolled products, with approximately 14 facilities in three geographically aligned business units in North America, Europe and China.  We serve a variety of end-use industries, including aerospace, automotive, defense, building and construction, transportation, packaging, and consumer goods.


    We are seeking to add a talented AOS Specialist - Reliable Assest to our Aleris Operating System (AOS) team.  The purpose of this role is to be a lead AOS team member on the implementation, training, teaching, coaching and management of a world class continuous improvement system utilizing lean and six sigma techniques in our Lewisport facility.  This position is a key support and tactical execution role of one of the cornerstones of our Aleris Operating System – Reliable Assets (Equipment).

    Responsibilities Include

    • Support the implementation of a world class AOS System: Reliable People (Lean Operations), Reliable Process (APC) and Reliable Assets (Equipment).
    • Teach and train the AOS curriculum for engineers, technical support, operations, maintenance and staff throughout the facility.
    • Provide coaching and mentoring of plant teams on the impact they have on equipment reliability.
    • Support the development of the plant Reliability Roadmap, maintain the map.
    • Support the development the plant Reliability Centered Maintenance program:
      • Provide coaching on condition based maintenance: Oil Analysis, Vibration Analysis, Infrared Imagining and Analysis, PDMA, etc.
      • Precision Maintenance: Laser Alignment, Lubrication Routes, Roll Management, etc.
      • PM (Preventative Maintenance) and PdM (Predictive Maintenance) systems
      • Asset Care Plans
      • Work Request, Work Management and Notification systems
      • Material Management, Spares and stores storage systems
    • Support the Plant and Regional Managers of Reliable Operations, Reliable Process and Reliable Assets through project work and data analysis.
    • Support the plant teams through facilitation and participation of advance problem solving techniques.
    • Demonstrate effective team facilitation skills to engage the various teams to deliver improvement results on time.
    • Implement the standardized AOS toolbox, including core tools: 5s, A3 Thinking, SMED, RCFA, TWI, Standardized Work, VSM, TPM, APC, Equipment Reliability and Problem Solving.
    • Coach, facilitate and participate in plant shop floor teams to enable Aleris to continuously improve performance, leverage Information Centers for continuous improvement and create a visual workplace, solve complex problems.
    • Interface with plant regional and global reliability resources and external consultants to benchmark and develop and closes gaps in the area of equipment reliability.
    • Develop and participate in Reliability auditing at all levels of the organization. Make recommendations and drive to implementing sustainable solutions.
    • Work with project engineering to ensure Design for Reliability concepts have been incorporated to ensure the maintainability of new and modified installations by using the life cycle asset management process.
    • Assist leadership in the development of strategic A3s for the business and plants.
    • Coordinate event follow-up (30/60/90 day reviews) to monitor the progress of planned improvement implementation to assure timely action, appropriate management support, and achievement of expected tangible benefits.
    • Lead and facilitate projects and/or events which address value-at-stake opportunities, helping to drive improvements in all facets of operations.
    • Participate in AOS and HSE audits. Drive solution implementation.
    • Identify and focus on short and long-term wins that will transform the culture and produce results.
    • Lead Root Cause Failure Analysis of significant People, Process, Equipment related downtime events at Plant locations; implement permanent corrective actions to mitigate probability of reoccurrence.
    • Facilitate FMEA(Failure Mode Effect Analysis) on equipment and processes within the facility.
    • Preform Analysis of Equipment Performance
      • Use statistical analysis techniques in the development of solutions to repetitive equipment failures and other equipment problems.
      • Coordinate the development, implementation and review the asset management strategy for each critical asset in the manufacturing unit.
    • Be a leader within the AOS organization – engage the workforce.
    • Openly and effectively communicate about continuous improvement, build credibility through relationships and provide leadership to the program.
    • Be a resource for operations, maintenance, HSE and supply chain in support of delivering the business objectives.
    • Use, teach and coach lean and six sigma methodology and proactive problem solving.
    • Spend 75% of working time at Gemba (on the plant floor) focusing on employee engagements.

    Required Qualifications

    • 2+ years of experience facilitating, coaching and implementing TPM, Lean, kaizen/six sigma events and driving lean transformation with proven results and implementations in a manufacturing environment.
    • Proven ability to work independently and successfully facilitate cross functional teams, while implement improvement within an established time frame.
    • Well organized, high energy, data driven and results oriented.
    • Excellent interpersonal, written, verbal communication skills and organization skills. Must be comfortable teaching and presenting to large groups at all levels of the organization from shop floor to CEO.
    • Must be proficient in MS Word, MS Excel, MS PowerPoint, MS Project, Oracle and various analysis tools (minitab, etc.).
    • Willingness to travel approximately 10% of the time.

    Preferred Qualifications

    • Bachelor degree strongly preferred, preferably in engineering, manufacturing/operations.
    • Aluminum Casting or Rolling Experience
    • Six Sigma Green/BlackBelt training/certification
    • CMRP or SMRP certification
    • Process/Technical/Operations/Maintenance experience

    Aleris is an equal opportunity employer and supports diversity in the workplace.  Qualified applications will receive consideration for employment without regard to their race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.  Our HR teams will reach out to the applicants who meet the qualifications and are most closely aligned with requirements of the position.


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